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BEST PRACTICES TOWARDS ENERGY BEST PRACTICES TOWARDS ENERGY

EFFICIENCYEFFICIENCY

UltraTech Cement Limited.UltraTech Cement Limited.UltraTech Cement Limited.UltraTech Cement Limited.

(Unit (Unit (Unit (Unit –––– Narmada Cement, Jafarabad Works)Narmada Cement, Jafarabad Works)Narmada Cement, Jafarabad Works)Narmada Cement, Jafarabad Works)

Narmada Cement-Jafarabad Works was established in 1982 with aninstalled capacity of 1 MMTPA clinker and has been graduallyincreased to 1.50 MMTPA (4,300 – 4,500 TPD). Cement capacity is0.50 MMTPA (1,150 TPD). The Unit is ISO 9001:2008, ISO14001:2004, OHSAS 18001:2007, ISMS 27001:2005 & SA8000:2008, ISO-50001:2011certified

It is India's first split location dry process cement plant with Fuller

Overview of NCJW

It is India's first split location dry process cement plant with Fullertechnology having four-stage suspension pre-heater, in-line flashcalciner, reverse air bag house dust collector, vertical roller millsbesides to be the first to unload imported South African coal at plantjetty. It transports 100% clinker to grinding units is in bulk by searoute. The special feature of this plant is 'Just in Time‘ design for rawmill circuit. As against conventional norms of 20,000 MT silo for rawmeal storage it has 2,000 MT silo.

The grinding units associated with Jafrabad Cement Works are Magdalla CementWorks having capacity of 0.80 MMTPA and Ratnagiri Cement Works havingcapacity of 0.50 MMTPA. All three coast-based split location units have Jetties formarine transportation. Narmada Cement was the prime supplier of fly ash basedPortland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada,which is the World's second largest concrete gravity dam (by volume). Wecreated a benchmark in Indian cement industry with installation of SF 3 X 6 cross

Overview of NCJW

created a benchmark in Indian cement industry with installation of SF 3 X 6 crossbar cooler supplied by FLS, in record 41 days.

With the hand holding of DuPont Sustainable Solutions, we are marching towards"Zero Accident" goal and articulating "Safety " as fundamental core belief withthe theme "Life is precious, We care for it" as advocated by Shri O PPuranmalka, Business Director. Moving ahead in the safety journey, we achievedlost time injury frequency rate (LTIFR) 0.00 in the year 2014-15.

ENERGY SAVING PROJECTSENERGY SAVING PROJECTS

4

1. Problem Statement: Dust settling in separator inlet duct.

2. Impact of Problem : Higher power consumption of separator fan to maintain the velocity in duct and maintain the DP in separator.

3. Action taken :� Separator all duct pressure readings were taken.� Dust settle point identified� Velocity measured in the separator inlet duct & found velocity was

lower than desired.

1.0 Case Study-Elimination of material settling at separator

inlet duct by providing hump to increase air velocity.

lower than desired.� It was decided to provide the hump in the inlet duct to increase the

velocity.� Hump size & location decided in the duct & provided.

Dust accumulation in duct

Before

Area Measurement UOM

Sep I/L Duct

Radius(Rb)1.5 Mtr

Duct Area 1.7671 M2

Flow 26.578 M3/Sec

Flow 95680 M3/Hr

Velocity 15.04 M/Sec

After

Area Measurement UOM

Radius (Ra) 1.25 Mtr

Duct Area 1.23 M2

Flow 26.578 M3/Sec

Flow 95680 M3/Hr

Velocity 21.66 M/Sec

Calculation for Hump size

Velocity 15.04 M/Sec Velocity 21.66 M/Sec

250mm

a532mm

Ø

Cos = (Height Of hump)/(a/2)

Height of hump = Rb-Ra

Cement angle of repose( )= 20

deg

Base of hump (a ) = 532mm

Ø

Ø

Before After

Separator Inlet Duct

Profile of dust settling inside duct

8

Hump in

separator inlet

duct

Hump view in separator

9

BEFORE AFTER

Previous fan power in KW 96Existing Fan running KW

84

Run Hrs 24 Run Hrs 24Power/Day 2304 Power/Day 2016Power per month 69120 Power per month 60480

Power Saving Calculation

Saving

Saving in energy KWh per year 103680

Saving in Lacs / Year (considering unit rate @ 4.85) 5.03

1. Problem Statement : High Pressure drop across the Preheater , High velocity at orifice because of high velocity difference in short span, Puffing occur at orifice.

2. Impact of Problem : High heat consumption across Preheater.

3. Action taken : Brought down the velocity at orifice to reduce

2.0 Reduction in heat losses across Preheater

3. Action taken : Brought down the velocity at orifice to reduce pressure drop across calciner

Existing

21.23

m/sec

21.23

m/sec

41.35

m/sec

Velocity 30m/Sec after orifice modification

21.23

m/sec

21.23

m/sec

30m/sec

Velocity at orifice at different location

12.09

m/sec

m/sec

12.09

m/sec

875 850

688650

902 880

600

700

800

900

1000

Kiln Feed PH Fan Speed PH O/L Temp

PH O/L Draft Calciner Exit Temp Calciner Exit Draft

Kiln feed Hood draft Kiln Riser DP Calciner Inlet Draft

Result

300 304382 386

11369

28 2784

4251 49

0

100

200

300

400

500

600

Before After

84

60

70

80

90

Kiln Riser DPBefore After

Result

42

0

10

20

30

40

50

60

Before After

2310

2157 2159 2152

906

899

894 893895

893

886

885

890

895

900

905

910

2150

2200

2250

2300

2350

KWH SG Fan RPM

Result

2157 21592143 2143 2152

20942062

877

860

865

870

875

880

885

1900

1950

2000

2050

2100

Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15

Month

Saving in Orifice Modification

Saving Average 280KWH of PH Fan

Kiln Running hours =345*24=8280

Result

=8280Total Saving in KWh =8280*248

=2053440Saving of Rs = 2053440 *4.67Rs/Unit

=95.89Lacs/Annum

•Increased insulation thickness in TAD from 65 to 100mm in 20m lining area

AFTERAFTERBEFOREBEFORE

3.0 Reduction in heat by increasing insulation in TA duct

•Backup Insulation of 35mm provided in Stage IV feed pipe.

AFTERAFTERBEFOREBEFORE

Result

•Before radiation losses with castable : 2.91 kCal/Kg of clinker

•After radiation losses with Brick lining : 2.22 kCal/Kg of clinker

Benefit in kCal/Hour : 129312.65Total Benefit in kCal kG/Clinker : 0.69

18

SNo. Title Action TakenSaving

KW/Month

1

Grinding aid motor running

with constant speed without

considering variation in Cement

mill Feed.

For optimizing Grinding Aid system

VFD installed. Now Motor speed is

varied with TPH.136.80

2

Pre grinder dust collector

material conveying air slide

blowers were running

Interlock provided such that if pre

grinder stopped two blowers stopped 1367.81

4. Various energy saving projects

2 blowers were running

continuously even if pre grinder

is kept stop condition.

grinder stopped two blowers stopped

after 10 min.

1367.81

3

Separator fan was running on

RPM basis so power is not

monitored, also due to material

settling in duct it was difficult

maintain the draft in circuit.

1) Sep. Fan control changed from

RPM base to KW base.

2) Trommel screen was taken in

operation to reduce the nibs

settling in duct

3) One hump is provided to increase

the velocity in duct.

17561.84

SNo. Title Action TakenSaving

KW/Month

4 Reduction in Mill fan RPM To maintain the mill discharge Blaine mill

fan rpm maintaining from 400 to 460.688.03

5Mill taking more power with

considering TPH.

Mill power optimized with maintaining the

media size & qty.7495.20

6

Pre grinder running hrs was

more because fresh feed was

Close loop system was developed and

feed was controlled w.r.t. reject .Through

put set point to be kept manually by 13200

4. Various energy saving projects

6 more because fresh feed was

monitoring manually.

put set point to be kept manually by

monitoring the crusher load.

13200

7

Separator motor was of old

version i.e. DC motor and taking

more power to operate.

Converted sep motor from DC to AC. 8208.00

Our Goal is to achieve Excellence in Our Goal is to achieve Excellence in

21

Energy ConservationEnergy Conservation

Thank You

Saving calculation of G-Aid motor after VFD.

Earlier motor KW----------A 0.37

After VFD motor running KW------B 0.18

Difference(A-B)---------C 0.19

Normal Day Run Hrs---------D 24Normal Day Run Hrs---------D 24

Saving in KW/Day (C X D)-------E 4.56

Saving in KW/Month (E X 30)-------F 136.8

Calculation-Earlier Condition

Motor rated KW 3.7

Operating KW 2.74

No. of blowers 2

Pre grinder running Hrs 15

Calculation-Existing Condition

Motor Rated KW 3.7

Operating KW 2.74

No. of blowers 2


Idle running for each stoppage 0.17

Saving calculation of Pre grinder blower

running hours


Idle running 9

Power/Day of both blowers 131.52

Idle running for each stoppage

of pre grinder0.17

Total start stop of Pre grinder 4

Total idle running Hrs 0.68

Power/day of both blowers 85.93

Saving in energy KWh per day 45.59

Saving in energy KWh per Month 1367.81

Power calculation on Last year performance

Operating current in

Amps 198.42

Operating KW 108.39

Power calculation on current year

performance

Fan running KW 84

Running Hrs 24

Saving calculation Cement Mill Separator fan

Operating KW 108.39

Running hours 24

Power/day in KWh 2601.395

Power per month in

KWh78041.84

Running Hrs 24

Power/Day in KWh 2016

Power per month in KWh 60480

Saving of KWh per month 17561.84

Saving calculation Cement mill fan


Operating current in Amps 8.8

Operating KW 4.81

Running hours 24


Power per month in KWh 3461.18

Power calculation on current year performance

Operating current in Amp 7.05

Operating KW 3.85

Running hours 24.00





Operating KW 1363.63

Running hours 24




Operating KW 1353.22

Running hours 24



Saving calculation Mill main Motor KW



Operating KW 140.00

Running hours 14

Power/day in KWh 1960

Power calculation on current year

performance

Operating KW 95.00

Running hours 16


Saving calculation of Pre grinder circuit






Power calculation on Earlier performance

2 Nos DC Motor Cooling fan operating

KW5.4

DC Motor operating KW 13.00

Total Power drawn by the separator

drive system.18.40


No Cooling fan for AC Motor. 0

Sep AC motor Operating KW 7.00

Total Power drawn by the Separator drive

system.7.00

Saving calculation of Cement mill separator

Motor from DC to AC

drive system.18.40

Running hours per day 24

Daily Power Consumption in KWh 441.6

Monthly Power Consumption in KWh 13248

Total Power drawn by the Separator drive

system.7.00

Running hours per day 24

Daily Power Consumption in KWh 168

Monthly Power Consumption in KWh 5040


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